Yamaha 2004 TT600RE Manuals

Yamaha 2004 TT600RE Manuals

Manuals and User Guides for Yamaha 2004 TT600RE. We have 2 Yamaha 2004 TT600RE manuals available for free PDF download: Service Manual

YAMAHA 2004 TT600RE Service Manual

YAMAHA 2004 TT600RE Service Manual (380 pages)

M.Y 1997-2007

Brand: YAMAHA | Category: Motorcycle | Size: 10.9 MB

Table of Contents

Table of Contents

4
- Chassis
  3
- Engine
  3
- General Information
  3
- Specifications
  3
- Troubleshooting
  3
  - Illustrated Symbols
    3
  - Table of Contents
    4
  - Gen Info
    6
- Chapter 1
  9
- Model Label
  9
- Vehicle Identification Number
  9
- Important Information
  10
  - Preparation for Removal Procedures
    10
  - Replacement Parts
    10
  - Gaskets, Oil Seals and O-Rings
    10
  - Lock Washers/Plates and Cotter Pins
    11
  - Bearings and Oil Seals
    11
  - Circlips
    11
- Checking of Connections
  12
- Special Tools
  13
Spec Chapter 2. Specifications

18
- Chapter 2. Specifications
  20
- General Specifications
  20
- Maintenance Specifications
  23
  - Engine
    23
  - Chassis
    31
  - Electrical
    36
- Conversion Table
  38
  - Engine
    39
  - Chassis
    40
- General Torque Specifications
  38
- Lubrication Layout
  41
- Cable Routing
  45
- Insp Adj
  50
Adj Periodic Inspection and Adjustments Chapter 3.

51
- Chapter 3. Periodic Inspection and Adjustments
  53
- Introduction
  53
- Periodic Maintenance/Lubrication Intervals
  53
- Seat, Fuel Tank and Rear Cowling
  55
  - Removal
    55
  - Installation
    55
- Engine
  56
  - Valve Clearance Adjustment
    56
  - Drive Chain Adjustment
    59
  - Idle Speed Adjustment
    59
  - Throttle Cable Free Play Adjustment
    60
  - Spark Plug Inspection
    61
  - Ignition Timing Check
    63
  - Compression Inspection
    64
  - Engine Oil Level Check
    67
  - Engine Oil Replacement
    69
  - Engine Oil Pressure Check
    73
  - Clutch Adjustment
    73
  - Air Filter Cleaning
    76
  - Fuel Filter Cleaning
    77
  - Engine Oil Tank Filter Cleaning
    78
  - Suction Hose and Manifold Inspection
    80
  - Fuel Line Inspection
    80
  - Exhaust System Inspection
    81
- Chassis
  82
  - Adjusting the Front Brake
    82
  - Adjusting the Rear Brake
    83
  - Checking the Brake Fluid Level
    84
  - Brake Pad Wear Inspection
    85
  - Brake Hosing Inspection
    85
  - Brake Circuit Bleeding
    86
  - Drive Chain Slack Inspection and Adjustment
    87
  - Drive Chain Lubrication
    88
  - Front Fork Inspection
    89
  - Adjusting the Front Fork
    89
  - Rear Shock Absorber Adjustment
    90
  - Steering Inspection
    92
  - Tyre Inspection
    93
  - Wheel Inspection
    96
  - Spoke Inspection and Tightening
    96
  - Cable Inspection
    97
  - Lever and Pedal Lubrication
    97
  - Sidestand Lubrication
    98
  - Rear Suspension Lubrication
    98
- Electrical System
  99
- Chas
  111
Chas Chapter 4. Chassis

112
- Chapter 4
  114
- Front Wheel and Brake Disc
  114
- Front Wheel and Brake Disc Removal
  114
- Front Wheel Disassembly
  116
- Front Wheel Inspection
  116
- Brake Disc Inspection
  118
- Front Wheel Assembly
  119
- Front Wheel Installation
  119
- Wheel Static Balance Adjustment
  119
- Front Brake
  121
  - Brake Pad Removal
    121
  - Brake Pad Replacement
    122
  - Master Cylinder
    124
  - Master Cylinder Inspection
    126
  - Master Cylinder Assembly
    126
  - Master Cylinder Installation
    127
  - Brake Caliper
    129
  - Brake Caliper Disassembly
    131
  - Caliper Inspection
    131
  - Caliper Assembly
    132
  - Caliper Installation
    132
- Rear Wheel and Brake Disc
  134
  - Rear Wheel and Brake Disc Removal
    134
  - Rear Wheel Disassembly
    136
  - Rear Wheel Inspection
    136
  - Brake Disc Inspection
    137
  - Rear Wheel Assembly
    138
  - Rear Wheel Installation
    138
  - Wheel Static Balance Adjustment
    140
- Rear Brake
  142
  - Brake Pad Removal
    142
  - Brake Pad Replacement
    142
  - Master Cylinder
    145
  - Master Cylinder Inspection
    146
  - Master Cylinder Assembly
    146
  - Master Cylinder Installation
    147
  - Brake Pedal Removal
    148
  - Brake Caliper
    149
  - Brake Caliper Disassembly
    151
  - Caliper Inspection
    151
  - Caliper Installation
    152
- Front Fork
  155
  - Front Fork Removal
    155
  - Front Fork Disassembly
    156
  - Front Fork Removal
    158
  - Oil Replacement
    159
  - Cleaning the Dust Seal
    162
  - Seal and Bush Replacement
    163
  - Oil Leakage from Dust Seal
    169
  - Anomalous Hydraulic Braking
    169
  - Front Fork Inspection
    170
  - Front Fork Installation
    172
  - Front Fork Adjustment
    172
- Steering
  174
  - Steering Removal
    177
  - Steering Inspection
    178
  - Steering Installation
    178
- Rear Shock Absorber
  182
  - Note on Disposal
    185
  - Shock Absorber Removal
    186
  - Shock Absorber Inspection
    187
  - Shock Absorber Adjustment
    187
- Swingarm
  189
  - Swingarm Removal
    190
  - Swingarm Inspection
    191
  - Lateral Free Play Adjustment
    192
  - Swingarm Installation
    193
- Drive Chain, Drive Sprocket and Rear Wheel Sprocket
  195
  - Drive Chain Removal
    195
  - Drive Chain Inspection
    196
  - Drive Chain Installation
    198
- Eng
  200
Eng Chapter 5. Engine

201
- Chapter 5
  203
- Engine Removal
  203
- Muffler, Exhaust Pipe, Engine Protector, Drive Sprocket Crankcase Cover, Drive Sprocket and Shift Pedal
  203
- Engine Mounting Bolt
  206
- Engine Disassembly
  207
  - Cylinder Head, Cylinder, Camshaft and Piston
    207
  - Intermediate Starter Gear, Crankcase Cover (L) and Generator Stator
    210
  - Crankcase Cover (R), Clutch, Primary Drive Gear and Balancer Shaft Gear
    211
  - Oil Pump and Shift Lever
    214
  - Ac Generator and Timing Chain
    215
  - Crankcase(R)
    216
  - Gearbox and Transmission
    218
  - Balancer Shaft and Crankshaft
    219
  - Oilstrainer
    219
  - Rocker Arms
    220
  - Valves
    221
- Inspection and Repair
  223
  - Cylinder Head
    223
  - Valves and Valve Guides
    224
  - Valveseat
    225
  - Valve Springs
    229
  - Camshaft
    230
  - Rocker Arms and Rocker Shaft
    230
  - Camshaft Chain and Sprocket
    231
  - Camshaft Chain Guide
    232
  - Cylinder and Piston
    232
  - Piston Rings
    234
  - Pistonpin
    235
  - Clutch
    235
  - Oilpump
    237
  - Transmission and Gearbox
    238
  - Starter Transmission
    240
  - Crankshaft
    241
  - Balancer Shaft Drive and Driven Gears
    242
  - Crankcase
    242
  - Bearing and Oil Seal
    242
- Engine Assembly and Setting
  244
  - Valves
    244
  - Rocker Arms
    245
  - Crankshaft and Balancer Shaft
    246
  - Transmission
    248
  - Gearbox
    249
  - Transmission and Gearbox
    250
  - Engine Oil Pump and Oil Strainer
    251
  - Crankcase
    252
  - Engine Oil Strainer
    253
  - Crankcase
    253
  - Shift Shaft and Oil Pump
    254
  - Timing Chain
    256
  - Piston and Rings
    257
  - Cylinder
    258
  - Cylinder Head
    259
  - Camshaft and Timing Chain
    260
  - Piston, Cylinder, Cylinder Head and Camshaft
    261
  - Ac Generator
    267
  - Oil Filter and Oil Hoses
    269
  - Balancer Shaft Gear and Primary Transmission Gear
    270
  - Clutch
    272
  - Starter Gears
    275
  - Starter Neutral Gear and Crankcase Cover (L)
    276
- Engine Reassembly
  278
- Carb
  281
- Elec
  300
Elec Chapter 7 Electrical

301
- Electrical Circuit Diagram
  303
- Chapter 7 Colour Code
  304
- Electrical Components
  305
- Switch Check
  307
  - Switch Connection
    307
  - Main Switch Inspection
    307
- Light Inspection (Headlights, Tail Light and Brake Lights, Direction Indicator Lights, Instrument Lights, Etc)
  310
  - Bulb Types
    310
  - Bulb Inspection
    310
- Ignition System
  313
  - Circuit Diagram
    313
  - Diagnostics
    315
- Electrical Starting System
  323
  - Circuit Diagram
    323
  - Starting Circuit Operation
    325
  - Diagnostics
    326
  - Starter Motor
    332
- Charging System
  337
  - Circuit Diagram
    337
  - Diagnostics
    339
- Light System
  343
  - Circuit Diagram
    343
  - Diagnostics
    345
  - Light System Inspection
    348
  - Circuit Diagram
    353
  - Diagnostics
    355
  - Signal System Control
    357
- Trbl Shtg
  367
? Trbl Shtg Chapter 8° Troubleshooting

368
- Chapter 8 °
  370
- Failure to Start/Difficulties in Starting
  370
- Fuel System
  370
- Electrical System
  371
- Poor Engine Compression
  371
- Poor Performance at Idle Speed
  372
- Unsatisfactory Performance at Medium-High Speed
  372
- Difficulties in Shifting
  373
  - Shifting Impossible
    373
  - The Shift Pedal Fails to Move
    373
  - Disengaging Gears
    373
- Clutch Slides or Fails to Release
  374
  - Clutch Slides
    374
  - Clutch Fails to Release
    374
- Defective Brakes
  375
  - Poor Braking
    375
- Oil Leaks or Malfunctioning of Front Fork
  375
  - Oil Leaks
    375
  - Malfunctioning
    375
- Unstable Steering
  376
- Defective Functioning of Lights and Indicators
  377
- Overheating of Engine
  378

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Yamaha 2004 TT600RE Service Manual

Yamaha 2004 TT600RE Service Manual (382 pages)

Brand: Yamaha | Category: Motorcycle | Size: 10.9 MB

Table of Contents

Table of Contents

6
- Chassis
  5
- Engine
  5
- General Information
  5
- Specifications
  5
- Troubleshooting
  5
  - Table of Contents
    6
- Gen Info
  8
- Model Label
  11
- Vehicle Identification Number
  11
- Gaskets, Oil Seals and O-Rings
  12
- Important Information
  12
- Preparation for Removal Procedures
  12
- Replacement Parts
  12
- Bearings and Oil Seals
  13
- Circlips
  13
- Lock Washers/Plates and Cotter Pins
  13
- Checking of Connections
  14
- Special Tools
  15
Spec Chapter 2. Specifications

20
- Chapter 2. Specifications
  22
- General Specifications
  22
- Engine
  25
- Maintenance Specifications
  25
- Chassis
  33
- Electrical
  38
- Conversion Table
  40
- General Torque Specifications
  40
- Engine
  41
- Chassis
  42
- Lubrication Layout
  43
- Cable Routing
  47
- Insp Adj
  52
Insp Adj Periodic Inspection and Adjustments Chapter 3.

53
- Chapter 3. Periodic Inspection and Adjustments
  55
- Introduction
  55
- Periodic Maintenance/Lubrication Intervals
  55
- Installation
  57
- Removal
  57
- Seat, Fuel Tank and Rear Cowling
  57
- Engine
  58
- Valve Clearance Adjustment
  58
- Drive Chain Adjustment
  61
- Idle Speed Adjustment
  61
- Throttle Cable Free Play Adjustment
  62
- Spark Plug Inspection
  63
- Ignition Timing Check
  65
- Compression Inspection
  66
- Engine Oil Level Check
  69
- Engine Oil Replacement
  71
- Clutch Adjustment
  75
- Engine Oil Pressure Check
  75
- Air Filter Cleaning
  78
- Fuel Filter Cleaning
  79
- Engine Oil Tank Filter Cleaning
  80
- Fuel Line Inspection
  82
- Suction Hose and Manifold Inspection
  82
- Exhaust System Inspection
  83
- Adjusting the Front Brake
  84
- Chassis
  84
- Adjusting the Rear Brake
  85
- Checking the Brake Fluid Level
  86
- Brake Hosing Inspection
  87
- Brake Pad Wear Inspection
  87
- Brake Circuit Bleeding
  88
- Drive Chain Slack Inspection and Adjustment
  89
- Drive Chain Lubrication
  90
- Adjusting the Front Fork
  91
- Front Fork Inspection
  91
- Rear Shock Absorber Adjustment
  92
- Steering Inspection
  94
- Tyre Inspection
  95
- Spoke Inspection and Tightening
  98
- Wheel Inspection
  98
- Cable Inspection
  99
- Lever and Pedal Lubrication
  99
- Rear Suspension Lubrication
  100
- Sidestand Lubrication
  100
- Checking and Charging the Battery
  101
- Electrical System
  101
- Checking the Fuses
  107
- Replacing the Headlight Bulbs
  108
- Replacing the Turn Indicator Light Bulb
  110
- Replacing the Tail/Brake Light Bulb
  111
- Chas
  113
Chas Chapter 4. Chassis

114
- Front Wheel and Brake Disc
  116
- Front Wheel and Brake Disc Removal
  116
- Front Wheel Disassembly
  118
- Front Wheel Inspection
  118
- Brake Disc Inspection
  120
- Front Wheel Assembly
  121
- Front Wheel Installation
  121
- Wheel Static Balance Adjustment
  121
- Brake Pad Removal
  123
- Front Brake
  123
- Brake Pad Replacement
  124
- Master Cylinder
  126
- Master Cylinder Assembly
  128
- Master Cylinder Inspection
  128
- Master Cylinder Installation
  129
- Brake Caliper
  131
- Brake Caliper Disassembly
  133
- Caliper Inspection
  133
- Caliper Assembly
  134
- Caliper Installation
  134
- Rear Wheel and Brake Disc
  136
- Rear Wheel and Brake Disc Removal
  136
- Rear Wheel Disassembly
  138
- Rear Wheel Inspection
  138
- Brake Disc Inspection
  139
- Rear Wheel Assembly
  140
- Rear Wheel Installation
  140
- Wheel Static Balance Adjustment
  142
- Brake Pad Removal
  144
- Brake Pad Replacement
  144
- Rear Brake
  144
- Master Cylinder
  147
- Master Cylinder Assembly
  148
- Master Cylinder Inspection
  148
- Master Cylinder Installation
  149
- Brake Pedal Removal
  150
- Brake Caliper
  151
- Brake Caliper Disassembly
  153
- Caliper Inspection
  153
- Caliper Installation
  154
- Front Fork
  157
- Front Fork Removal
  157
- Front Fork Disassembly
  158
- Front Fork Removal
  160
- Oil Replacement
  161
- Cleaning the Dust Seal
  164
- Seal and Bush Replacement
  165
- Anomalous Hydraulic Braking
  171
- Oil Leakage from Dust Seal
  171
- Front Fork Inspection
  172
- Front Fork Adjustment
  174
- Front Fork Installation
  174
- Steering
  176
- Steering Removal
  179
- Steering Inspection
  180
- Steering Installation
  180
- Rear Shock Absorber
  184
- Note on Disposal
  187
- Shock Absorber Removal
  188
- Shock Absorber Adjustment
  189
- Shock Absorber Inspection
  189
- Swingarm
  191
- Swingarm Removal
  192
- Swingarm Inspection
  193
- Lateral Free Play Adjustment
  194
- Swingarm Installation
  195
- Drive Chain Removal
  197
- Drive Chain, Drive Sprocket and Rear Wheel Sprocket
  197
- Drive Chain Inspection
  198
- Drive Chain Installation
  200
- Eng
  202
Eng Chapter 5. Engine

203
- Engine Removal
  205
- Muffler, Exhaust Pipe, Engine Protector, Drive Sprocket Crankcase Cover, Drive Sprocket and Shift Pedal
  205
- Engine Mounting Bolt
  208
- Cylinder Head, Cylinder, Camshaft and Piston
  209
- Engine Disassembly
  209
- Intermediate Starter Gear, Crankcase Cover (L) and Generator Stator
  212
- Crankcase Cover (R), Clutch, Primary Drive Gear and Balancer Shaft Gear
  213
- Oil Pump and Shift Lever
  216
- Ac Generator and Timing Chain
  217
- Crankcase(R)
  218
- Gearbox and Transmission
  220
- Balancer Shaft and Crankshaft
  221
- Oilstrainer
  221
- Rocker Arms
  222
- Valves
  223
- Cylinder Head
  225
- Inspection and Repair
  225
- Valves and Valve Guides
  226
- Valveseat
  227
- Valve Springs
  231
- Camshaft
  232
- Rocker Arms and Rocker Shaft
  232
- Camshaft Chain and Sprocket
  233
- Camshaft Chain Guide
  234
- Cylinder and Piston
  234
- Piston Rings
  236
- Clutch
  237
- Pistonpin
  237
- Oilpump
  239
- Transmission and Gearbox
  240
- Starter Transmission
  242
- Crankshaft
  243
- Balancer Shaft Drive and Driven Gears
  244
- Bearing and Oil Seal
  244
- Crankcase
  244
- Engine Assembly and Setting
  246
- Valves
  246
- Rocker Arms
  247
- Crankshaft and Balancer Shaft
  248
- Transmission
  250
- Gearbox
  251
- Transmission and Gearbox
  252
- Engine Oil Pump and Oil Strainer
  253
- Crankcase
  254
- Crankcase
  255
- Engine Oil Strainer
  255
- Shift Shaft and Oil Pump
  256
- Timing Chain
  258
- Piston and Rings
  259
- Cylinder
  260
- Cylinder Head
  261
- Camshaft and Timing Chain
  262
- Piston, Cylinder, Cylinder Head and Camshaft
  263
- Ac Generator
  269
- Oil Filter and Oil Hoses
  271
- Balancer Shaft Gear and Primary Transmission Gear
  272
- Clutch
  274
- Starter Gears
  277
- Starter Neutral Gear and Crankcase Cover (L)
  278
- Engine Reassembly
  280
- Carb
  283
- Elec
  302
Elec Chapter 7 Electrical

303
- Electrical Circuit Diagram
  305
- Colour Code
  306
- Electrical Components
  307
- Main Switch Inspection
  309
- Switch Check
  309
- Switch Connection
  309
- Bulb Inspection
  312
- Bulb Types
  312
- Light Inspection (Headlights, Tail Light and Brake Lights, Direction Indicator Lights, Instrument Lights, Etc)
  312
- Circuit Diagram
  315
- Ignition System
  315
- Diagnostics
  317
- Circuit Diagram
  325
- Electrical Starting System
  325
- Starting Circuit Operation
  327
- Diagnostics
  328
- Starter Motor
  334
- Charging System
  339
- Circuit Diagram
  339
- Diagnostics
  341
- Circuit Diagram
  345
- Light System
  345
- Diagnostics
  347
- Light System Inspection
  350
- Circuit Diagram
  355
- Diagnostics
  357
- Signal System Control
  359
- Trbl Shtg
  369
? Trbl Shtg Chapter 8° Troubleshooting

370
- Failure to Start/Difficulties in Starting
  372
- Fuel System
  372
- Electrical System
  373
- Poor Engine Compression
  373
- Poor Performance at Idle Speed
  374
- Unsatisfactory Performance at Medium-High Speed
  374
- Difficulties in Shifting
  375
- Disengaging Gears
  375
- Shifting Impossible
  375
- The Shift Pedal Fails to Move
  375
- Clutch Fails to Release
  376
- Clutch Slides
  376
- Clutch Slides or Fails to Release
  376
- Defective Brakes
  377
- Malfunctioning
  377
- Oil Leaks
  377
- Oil Leaks or Malfunctioning of Front Fork
  377
- Poor Braking
  377
- Unstable Steering
  378
- Defective Functioning of Lights and Indicators
  379
- Direction Indicators Fail to Turn off
  379
- Direction Indicators Fail to Turn on
  379
- Frequent Burning of Bulb
  379
- Delayed Turning on of Indicators
  380
- Excessive Indicator Intermittence Frequency
  380
- Overheating of Engine
  380
- The Horn Fails to Work
  380

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